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Although polystyrene microspheres are often the seed material of choice for subsonic airflow studies. These seed materials, however, do not provide any benefit for near wall measurements compared to other state-of-the-art seed materials. Consequently, in this innovation NASA scientists have developed this method of generating dye-doped polystyrene microspheres using novel synthetic approaches. The novel features of this invention are the utility of specific chemical functionalities, monomeric species, environmental additives (buffers), and polyelectrolytes to promote incorporation of dye molecules into developing polystyrene microspheres while enabling control of the spectral properties of the dye relative to pH dependence. These particles will have great utility for wind tunnel measurements near the wall where the state-of-the-art seed materials are not able to collect data. Additionally, the incorporation of these dyes will offer other avenues of data collection including temperature and pressure of the airflows and wind tunnel regions. Likewise, the ability to selectively filter the data collected from these dye-doped polystyrene microspheres can have further applications including the direct visualization of 2 or more fluid flows mixing, among other applications.

NASA’s pneumatic nail penetration trigger system embodies a fast and consistent nail penetration and retraction tool that tests battery cells within various steel and mylar enclosures. It is operated remotely with electric power and shop air pressure inputs. The trigger system is controlled by a solenoid valve and drives a nail to a set distance at 100 m/s for a precise and repeatable penetration injury to a battery cell. Contributing to the trigger system’s precision and repeatability is the nail penetration adapter that aligns the battery cell test enclosure with the trigger system and guides the nail by its internal barrel. The tip of the adapter threads into a variety of NASA battery cell test enclosures and provides an internal seating stop to ensure a proper targeting depth. On the actuator side of the adapter, two quick-release pins connect the adapter to the actuator mount which is bolted to the actuator subassembly. Removal of these pins readily allow for separation of the nail penetration adapter from the actuator mount and subassembly. During a TR event, the adapter is also designed to prevent flames, sparks, and ejecta from traveling into the actuator subassembly. While the versatile nail penetration adapter was originally configured to interface with NASA’s Fractional Thermal Runaway Calorimeter (FTRC), a blast plate test platform (BPTP), or cell enclosure for passive propagation resistant (PPR) methods, the adapter could be modified for commercial use with other battery testing systems. Companies interested in this technology may include those seeking to improve the safety of Li-ion battery cells and packs along with vertically integrated companies performing in-house TR tests during development of electrified systems like electric vehicles (EVs), electric vertical takeoff and landing (eVTOLs) vehicles, and electronic spacecraft components.

The technology utilizes four cutting-edge sensor technologies to enable minimally- or non-invasive analysis of various biological samples, including saliva, breath, and blood. The combination of technologies and sample pathways have unique advantages that collectively provides a powerful analytical capability. The four key technology components include the following: (1) the carbon nanotube (CNT) array designed for the detection of volatile molecules in exhaled breath; (2) a breath condenser surface to isolate nonvolatile breath compounds in exhaled breath; (3) the miniaturized differential mobility spectrometer (DMS) -like device for the detection of volatile and non-volatile molecules in condensed breath and saliva; and (4) the miniaturized circular disk (CD)-based centrifugal microfluidics device that can detect analytes in any liquid sample as well as perform blood cell counts. As an integrated system, the device has two ports for sample entry a mouthpiece for sampling of breath and a port for CD insertion. The breath analysis pathway consists of a CNT array followed by a condenser surface separating liquid and gas phase breath. The exhaled breath condensate is then analyzed via a DMS-like device and the separated gas breath can be analyzed by both CNT sensor array again and by DMS detectors.

NASA’s electrochemical Enzyme-Linked Immunosorbent Assay (ELISA) microelectrode array biosensor advantageously incorporates a microbead detection construct, coupled with a magnetic immobilization construct, which substantially increases the signal sensitivity of a sensor. The magnetic immobilization construct draws the microbead detection construct to an electrode detection surface, enhancing signal sensitivity. By concentrating the signaling molecules close to the electrode detection surface, electrochemical redox cycling is achieved by reducing the distance between the two, allowing for regeneration of reporter molecules. Whereas a traditional ELISA testing exhibits five to ten signaling molecules per probe molecule binding event, the present electrochemical ELISA-based biosensor testing exhibits up to 4,857 signaling molecules per probe molecule binding event. The model bead construct exhibits a more than 6.75-fold in increased measured signal, and more than 35.7-fold improvement in signal sensitivity. When compared to traditional optical ELISA, the present invention improves the limit of detection by up to a factor of 60.5. NASA’s electromagnetic ELISA-based biosensor can be used for the detection of SARS-CoV-2 virus to enhance Covid-19 testing during the early phases of infection. The technology may also be modified to detect other biomarkers.

In order to maintain the low cost, simplicity, and quick turnaround of cold-flow testing while improving accuracy, NASA evaluated unconventional gases for use as simulants. During such evaluations, NASA discovered that by adjusting stagnation temperature, the isentropic exponent of ethane can be tuned to approximate those of common rocket propellants (e.g., hydrogen, hypergols, alcohols, and hydrocarbons). Furthermore, due to ethanes high auto-ignition temperature and resistance to condensation, tuned ethane enables testing of expansion ratios much larger than conventional inert-gas testing. To leverage this discovery, NASA developed a hardware-based system to treat ethane and obtain nozzle chamber conditions that match the appropriate aerodynamics for a specific test. The system, named HYPERFIRE, works in the following manner. Liquid ethane is transferred to a piston-style run tank, where it is pressurized. Then, the ethane is run through two insulated pebble beds where it is heated, vaporized, and stabilized. Finally, the treated ethane is transferred from the second pebble bed to a small thrust takeout structure, and through the test article. Control of valves and regulators is managed by an onboard computer, accessed via a LabVIEW™ interface. The system is mounted on a hurricane-resistant steel frame to enable transportation via forklift. Heated ethane reproduces the aerodynamics of combustion products at low temperatures relative to alternative testing methods. Thus, test articles can be manufactured using low-cost, low temperature rated, transparent materials (e.g., acrylic). In addition to reducing testing cost, this grants optical access to internal flowfields, enabling advanced diagnostic techniques (e.g., Schlieren imaging, particle image velocimetry) not possible with hot-fire testing and less meaningful with conventional cold-flow testing.

Combining a dynamic load emulation technique with a PWM dithering technique, NASA’s technology provides a more efficient, cost-effective, and practical method to emulate complex loads. While there are commercially available electronic device loads on the market that meet basic emulation needs, these devices are limited; they are limited with respect to small input voltage changes, and to feedback signals from the device’s power system, which may lack the strength and resolution needed to emulate accurately. A common solution for the bus emulation limitation is to construct a model of an actual microgrid using representative loads and connections. But this can be complex, costly, and have limitations in performance. NASA’s approach addresses these challenges without creating an actual model microgrid to replicate the systems. As opposed to stand-alone COTS electronic load devices or model microgrids using representative loads and connections for a given test, NASA’s technology is a system constructed of an input power filter, a COTS electronic load device or load subsystem, and a power control circuit. The input power filter is designed to emulate load or bus performance at the medium to high frequency range. The power control circuit combined with the electronic load or load subsystem emulates lower frequency and constant power dynamics of the system. Lastly, the power control circuit linearizes digitization and quantization issues present with digitally controlled COTS electronic loads. The power control circuit can be set to measure a load voltage, which is divided by a determined value for power, and combined with a triangle wave dither (the power control circuit block image demonstrates how to integrate a triangle wave dither). This dither dynamically adjusts the electrical current or power to keep it constant within the commercially purchased load device, enabling accurate emulation of complex DC microgrid systems.

This NASA-developed eVTOL UAS is a purpose-built, electric, reusable aircraft with rotor/propeller thrust only, designed to fly trajectories with high similarity to those flown by lunar landers. The vehicle has the unique capability to transition into wing borne flight to simulate the cross-range, horizontal approaches of lunar landers. During transition to wing borne flight, the initial transition favors a traditional airplane configuration with the propellers in the front and smaller surfaces in the rear, allowing the vehicle to reach high speeds. However, after achieving wing borne flight, the vehicle can transition to wing borne flight in the opposite (canard) direction. During this mode of operation, the vehicle is controllable, and the propellers can be powered or unpowered. This NASA invention also has the capability to decelerate rapidly during the descent phase (also to simulate lunar lander trajectories). Such rapid deceleration will be required to reduce vehicle velocity in order to turn propellers back on without stalling the blades or catching the propeller vortex. The UAS also has the option of using variable pitch blades which can contribute to the overall controllability of the aircraft and reduce the likelihood of stalling the blades during the deceleration phase. In addition to testing EDL sensors and precision landing payloads, NASA’s innovative eVTOL UAS could be used in applications where fast, precise, and stealthy delivery of payloads to specific ground locations is required, including military applications. This concept of operations could entail deploying the UAS from a larger aircraft.

In vitro three-dimensional (3D) human broncho-epithelial (HBE) tissue-like assemblies (3D HBE TLAs or TLAs) were engineered in modeled microgravity using rotating wall vessel technology (pictured above) to mimic the characteristics of in vivo tissue. The TLAs were bioengineered onto collagen-coated cyclodextran beads using primary human mesenchymal bronchial-tracheal cells (HBTC) as the foundation matrix and an adult human broncho-epithelial immortalized cell line (BEAS-2B) as the overlying component. The resulting TLAs share significant characteristics with in vivo human respiratory epithelium including polarization, tight junctions, desmosomes, and microvilli. The presence of tissue-like differentiation markers including villi, keratins, and specific lung epithelium markers, as well as the production of tissue mucin, further confirm these TLAs have differentiated into tissues functionally like in vivo tissues. TLAs mimic aspects of the human respiratory epithelium and provide a unique capability to study the interactions of respiratory viruses and their primary target tissue independent of the host's immune system. The innovation "Methods For Growing Tissue-Like 3D Assemblies Of Human Broncho-Epithelial Cells" is at Technology Readiness Level (TRL) 6 (which means system/subsystem prototype demonstration in a relevant environment) and the related patent is now available to license for development into a commercial product. Please note that NASA does not manufacture products itself for commercial sale.

Spark-ignition devices have proven to be a high-reliability option for LOX/LCH4 ignition during development of the Integrated Cryogenic Propulsion Test Article (ICPTA) main and reaction control engines (RCEs); however, issues including spark plug durability (ceramic cracking) and corona discharge during simulated altitude testing have been observed, contributing to degraded spark output and no-light engine-start conditions. Innovators discovered that ignition system reliability could be improved and weight reduced by eliminating the traditional coil and spark plug wire. To achieve this result, engineers made the innovation by modifying an automotive coil-on-plug igniter to provide new high sparking energies at the point of combustion using low supply voltages. The coil was modified by vacuum-potting it into a threaded interface that mounts into existing spark plug ports on the ICPTA main engine and the RCEs. Engineers fabricated custom electrode tips that were thread-mounted into the potted coil body. Epoxy insulation was chosen with high dielectric strength to maintain insulation between the electrode and threaded adapter. Vacuum potting successfully prevented pressure or vacuum leakage into the coil body and maintained spark energy and location at the electrode tip. Successful hot-fire ignition was observed at sea-level, altitude, and thermal-vacuum for both ICPTA RCE and main engine igniters down to 10^-3 torr, which approaches the vacuum of cislunar space. This technology is at technology readiness level (TRL) 7 (system prototype demonstration in an operational environment), and the related patent is now available to license. Please note that NASA does not manufacture products itself for commercial sale.

Going farther, faster and hotter in space means innovating how NASA constructs the materials used for heat shields. For HEEET, this results in the use of dual-layer, three-dimensional, woven materials capable of reducing entry loads and lowering the mass of heat shields by up to 40%. The outer layer, exposed to a harsh environment during atmospheric entry, consists of a fine, dense weave using carbon yarns. The inner layer is a low-density, thermally insulating weave consisting of a special yarn that blends together carbon and flame-resistant phenolic materials. Heat shield designers can adjust the thickness of the inner layer to keep temperatures low enough to protect against the extreme heat of entering an atmosphere, allowing the heat shield to be bonded onto the structure of the spacecraft itself. The outer and inner layers are woven together in three dimensions, mechanically interlocking them so they cannot come apart. To create this material, manufacturers employ a 3-D weaving process that is similar to that used to weave a 2-D cloth or a rug. For HEEET, computer-controlled looms precisely place the yarns to make this kind of complex three-dimensional weave possible. The materials are woven into flat panels that are formed to fit the shape of the capsule forebody. Then the panels are infused with a low-density version of phenolic material that holds the yarns together and fills the space between them in the weave, resulting in a sturdy final structure. As the size of each finished piece of HEEET material is limited by the size of the loom used to weave the material, the HEEET heat shield is made out of a series of tiles. At the points where each tile connects, the gaps are filled through inventive designs to bond the tiles together.